Risk

Risk Register

Severity × probability across all mapped compliance risks.

Risk Matrix

Critical

High

Medium

Low

Probability →

Risk	Severity	P	Score	Mitigation
Accidental detonation during mixing	Critical	4	80	Remote operation, shielding per UFC 3-340-02, and explosives safety review prior to start-up.
Dust deflagration in collection system	Critical	3	60	Remote operation, shielding per UFC 3-340-02, and explosives safety review prior to start-up.
Procurement of non-ASME vessel	High	4	60	Engineering controls, third-party verification and AHJ acceptance testing.
Unapproved European Ex equipment installed	High	4	60	Engineering controls, third-party verification and AHJ acceptance testing.
Inadequate hazardous ventilation	High	3	45	Engineering controls, third-party verification and AHJ acceptance testing.
Incorrect area classification	High	3	45	Engineering controls, third-party verification and AHJ acceptance testing.
Static ignition of propellant dust	High	3	45	Engineering controls, third-party verification and AHJ acceptance testing.
Fire suppression response time inadequate	High	3	45	Engineering controls, third-party verification and AHJ acceptance testing.
Cyber intrusion on PLC network	High	3	45	Engineering controls, third-party verification and AHJ acceptance testing.
Schedule delay from submittal rejection	Medium	4	40	Administrative controls, periodic inspection and documented procedures.
Insufficient QD separation	Critical	2	40	Remote operation, shielding per UFC 3-340-02, and explosives safety review prior to start-up.
Extruder thermal runaway	Critical	2	40	Remote operation, shielding per UFC 3-340-02, and explosives safety review prior to start-up.
Arc flash at switchgear	High	2	30	Engineering controls, third-party verification and AHJ acceptance testing.
Loss of fire water supply	High	2	30	Engineering controls, third-party verification and AHJ acceptance testing.
Toxic solvent vapor exposure	Medium	3	30	Administrative controls, periodic inspection and documented procedures.
SIS spurious trip impacting production	Medium	3	30	Administrative controls, periodic inspection and documented procedures.
Overpressure of pressure vessel	High	2	30	Engineering controls, third-party verification and AHJ acceptance testing.
Unauthorized access to energetic storage	High	2	30	Engineering controls, third-party verification and AHJ acceptance testing.
Hazardous waste permit violation	Medium	3	30	Administrative controls, periodic inspection and documented procedures.
Air permit exceedance	Medium	2	20	Administrative controls, periodic inspection and documented procedures.
Lightning strike in explosive area	Medium	2	20	Administrative controls, periodic inspection and documented procedures.
Crane load drop on energetics	Critical	1	20	Remote operation, shielding per UFC 3-340-02, and explosives safety review prior to start-up.
Generator failure during emergency	Medium	2	20	Administrative controls, periodic inspection and documented procedures.
Documentation not in English	Low	4	20	Track in submittal register and resolve during design review.
Blast door failure	High	1	15	Engineering controls, third-party verification and AHJ acceptance testing.